Perfect Biogas Generators - 3 kVa to 160 kVa
Perfect Biogas supplies biogas generators (gensets) engineered specifically for biogas fuel from 3 kVa to 160 kVa capacity. Unlike standard diesel or natural gas generators, our biogas gensets feature modified combustion chambers, ignition systems, and carburetion to handle biogas's unique properties - lower energy density, variable methane content (55-70%), and corrosive H₂S traces.
With 25+ years experience, we've supplied 300+ biogas generators across dairy farms, poultry operations, municipal waste plants, and industrial facilities, delivering reliable 24x7 power with 90-95% uptime and minimal maintenance.
Why Biogas Generators Over Grid Power?
- Zero Fuel Cost: Free energy from on-site biogas (vs. ₹7-10/kWh grid)
- Energy Independence: Unaffected by grid failures, load shedding
- Carbon Negative: Offset 1 ton CO₂ per MWh generated (vs. coal grid)
- Waste Management: Solve waste disposal while generating power
- Dual Fuel Option: Automatic diesel backup when biogas low
- Net Metering: Sell excess power to grid (open access/wheeling)
Generator Range & Applications
| Capacity |
Biogas Required |
Typical Application |
Price Range |
| 3-5 kVa |
1.5-2.5 m³/hr |
Small dairy (5-10 cattle), Household |
₹1.2-1.8 Lakhs |
| 10-15 kVa |
5-7.5 m³/hr |
Medium dairy (20-30 cattle), Hostel |
₹2.5-3.5 Lakhs |
| 25-35 kVa |
12-17 m³/hr |
Large dairy (50-80 cattle), Hotel |
₹5-7 Lakhs |
| 62.5 kVa |
30-35 m³/hr |
Poultry farm, Food processing |
₹12-15 Lakhs |
| 100 kVa |
50-55 m³/hr |
Industrial biogas, MSW plant |
₹20-25 Lakhs |
| 125-160 kVa |
60-80 m³/hr |
Large industrial, Municipality |
₹28-35 Lakhs |
Note: Prices include engine, alternator, cooling system, control panel, AMF. Excludes installation, civil work.
Technical Specifications
Engine Modifications for Biogas
- Compression Ratio: Reduced to 10-11:1 (vs. 17-20:1 diesel) to prevent knocking
- Spark Ignition: Added CDI system with high-energy coils (biogas needs spark vs. diesel compression)
- Mixing Venturi: Gas-air carburetor ensures stoichiometric 1:10 ratio
- Corrosion-Resistant Valves: Inconel/stellite facing to handle H₂S
- Wider Valve Timing: Compensates for slower biogas flame speed
Cooling Systems
Air-Cooled (3-15 kVa):
- Finned cylinder block with forced-air blower
- Suitable for intermittent duty (8-10 hrs/day)
- Lower cost, simpler maintenance
- Noisier operation (75-85 dB at 7m)
Water-Cooled (15-160 kVa):
- Closed-loop radiator system with thermostatic control
- Designed for continuous 24x7 duty
- Quieter (65-70 dB in acoustic canopy)
- Higher cost but longer lifespan (20,000+ hours)
Control Panel Features
- Digital Display: RPM, voltage, current, power factor, frequency, run hours
- Auto Start/Stop: Programmable time-based or load-based operation
- AMF (Auto Mains Failure): Switches to biogas genset within 10 seconds of grid failure
- Load Sharing: Parallel operation of multiple gensets for redundancy
- Remote Monitoring: GSM/WiFi connectivity for SMS/email alerts
- Safety Interlocks: Low oil pressure, high temperature, overcurrent trip
Gas Conditioning Requirements
Raw biogas needs treatment before genset use:
Moisture Removal
- Biogas exits digester saturated with water vapor (100% RH)
- Cool gas to 10-15°C in chiller/condenser to precipitate water
- Install drip leg with auto drain valve every 10m of gas line
- Risk if not done: Water damages carburetor, causes engine misfire
H₂S Scrubbing
- H₂S content in raw biogas: 500-3000 ppm (corrosive to engine)
- Target: <100 ppm for safe genset operation
- Methods: Iron sponge filter (₹15,000-40,000), bio-scrubbing tower (₹2-5 Lakhs)
- Maintenance: Replace iron sponge every 6-12 months
Pressure Regulation
- Generator requires stable 50-150 mbar gas pressure
- Install pressure regulator + gauge before carburetor
- Gas storage (4-8 hours) ensures continuous supply during low production periods
Installation Requirements
Genset Room Specifications
- Area: 2x genset footprint (e.g., 25 kVa needs 15-20 sq.m)
- Ventilation: Inlet + exhaust fans for heat dissipation (0.05 m²/kW)
- Exhaust System: Silencer + 4-6m vertical stack for gas venting
- Foundation: 150mm RCC plinth with vibration dampers
- Gas Pipeline: GI/HDPE pipe (DN25-DN50) from digester to genset
- Electrical Panel: Separate 2m x 1m room for switchgear, transformer
Operation & Maintenance
Daily Checks (5-10 minutes)
- Engine oil level (top-up if below midmark)
- Coolant level in radiator (water-cooled models)
- Biogas pressure gauge (should be 80-120 mbar)
- Note running hours, voltage, frequency from display
Weekly Maintenance
- Drain water condensate from drip legs
- Clean air filter (blow compressed air)
- Check battery terminals for corrosion
- Inspect for gas leaks (soap water test)
Monthly Service
- Engine oil + filter change (every 250-300 hours)
- Check spark plug gap (0.7-0.8mm), replace if worn
- Tighten loose nuts/bolts from vibration
- Clean H₂S scrubber (replace if saturated)
Annual Overhaul
- Valve clearance adjustment
- Cylinder compression test
- Replace coolant, timing belt (water-cooled)
- Alternator bearing regreasing
- Cost: ₹20,000-50,000 depending on capacity
Performance & Efficiency
- Electrical Efficiency: 25-32% (biogas to AC electricity)
- Heat Recovery: CHP (combined heat & power) captures 40-50% as hot water
- Overall Efficiency: 70-80% with cogeneration
- Fuel Consumption: 0.5-0.6 m³ biogas per kWh generated
- Uptime: 90-95% with preventive maintenance
- Lifespan: 15,000-25,000 hours (water-cooled), 7,000-12,000 hours (air-cooled)
Economics Example
62.5 kVa Biogas Generator for 25,000 Bird Poultry Farm
- Genset Cost: ₹13 Lakhs (with canopy, control panel)
- Installation: ₹2 Lakhs (civil, piping, electrical)
- Total Investment: ₹15 Lakhs
Annual Generation & Savings:
- Running hours: 20 hrs/day × 330 days = 6,600 hrs/year
- Electricity: 62.5 kW × 6,600 hrs = 4.125 Lakh kWh/year
- Savings at ₹8/kWh: ₹33 Lakhs/year
- Less: Maintenance (₹3.5 Lakhs/year)
- Net Savings: ₹29.5 Lakhs/year
- Payback: 6 months (biogas plant already exists)
Dual Fuel Option
For critical loads requiring 100% uptime:
- Generator runs 90% on biogas, 10% pilot diesel injection
- Automatic switchover to 100% diesel if biogas pressure drops
- Adds ₹1-1.5 Lakhs to genset cost
- Recommended for hospitals, data centers, cold storage
Grid Synchronization
For selling excess power or net metering:
- Components: Synchroscope, auto-sync panel, reverse power relay
- Cost: ₹1.5-3 Lakhs (25-100 kVa)
- Approval: State electricity board NOC required (30-60 days)
- Revenue: Sell at ₹4-5/kWh (avoided cost rate) or PPA
Top Brands We Supply
- Cummins India: 25-160 kVa, best for 24x7 industrial duty
- Kirloskar Green: 10-62.5 kVa, economical for dairy/poultry
- Greaves Power: 3-35 kVa, compact air-cooled models
- MWM (Germany): 100-500 kW, best efficiency for mega projects
- Jenbacher (Austria): 500 kW-5 MW, ultra-low emissions for CBG plants
Warranty & AMC
- Standard Warranty: 1 year / 2,000 running hours (whichever earlier)
- Extended Warranty: Up to 5 years / 10,000 hours available
- AMC Plans: ₹30,000-1,50,000/year (quarterly service, spares, emergency support)
- Response Time: 24 hours for major cities, 48 hours tier-2/3 cities
- Spares Availability: Common parts stocked (spark plug, filters, belts)
Why Choose Perfect Biogas Generators?
- 300+ Installations: Proven reliability across diverse applications
- Biogas-Optimized: Not retrofitted diesel gensets, designed for biogas from ground up
- Complete System: Gas scrubbing, chilling, genset, synchronization - single vendor
- Training Provided: 2-day operator training on-site, SOP manuals
- Remote Monitoring: IoT dashboard tracks performance 24x7
- Pan India Service: 50+ service engineers across all states
Request Generator Sizing & Quote
Share your biogas production rate and electricity requirement. We'll recommend the optimal genset configuration and provide detailed quotation.
Contact Generator Division:
← Back to Homepage